Investigating the Surface Quality of Aramid Honeycomb Materials Through Longitudinal–Torsional Ultrasonic Milling

During the milling process of aramid honeycomb, residual stresses arise, which will affect the surface quality of the honeycomb. Studies have shown that reasonable processing techniques can reduce residual stresses, indicating a close relationship between residual processing stresses and the processing parameters, such as technique. By investigating the changes in residual stresses after the processing of aramid honeycomb materials, the influence of processing techniques on these changes is analyzed. Leveraging the correlation between residual stresses and surface quality, this study proposes the use of residual stress as an indicator for evaluating processing techniques. The longitudinal–torsional ultrasonic vibration milling method is applied to the processing of aramid honeycombs. A single-factor experimental approach is adopted, utilizing ABAQUS 2020 software to mimic the longitudinal–torsional ultrasonic milling process. This study explores the influence patterns of various process parameters on the residual stresses generated during the milling of honeycombs. The simulation results indicate that within the selected range, the residual stress decreases as the tool rotation speed increases, while it increases with the increase in feed rate. The influence of milling depth on residual stress can be negligible. Furthermore, experiments were conducted based on the proposed correlation between residual stress and surface quality. The experimental results show good agreement with the simulation results, indicating that under reasonable process parameters, the residual stress values decrease, thereby improving the milling surface quality of aramid honeycomb materials. Therefore, measuring residual stress can serve as an effective method for evaluating the processing technique.